Sharps container

ABSTRACT

A container for disposal of medical waste is provided that comprises a receptacle with an open top. A lid is attached to the receptacle to cover the open top of the receptacle. The lid has an elongated opening sized to permit the introduction of medical waste into the receptacle. A closure flap is connected to the lid to selectively close the lid opening. The closure flap is movable between an open position, a closed position and a locked position. The closure flap is attached to the lid by axial hubs that extend from each side of the closure flap through openings in the side walls of the lid. Covers attached to the outside of the side wall of the lid and engaged with the closure flap axial hub. The container may also include a locking external cabinet that encloses the receptacle and can be mounted to a wall.

RELATED APPLICATIONS

The present invention is a continuation of U.S. patent application Ser.No. 16/436,920, filed Jun. 11, 2019, now U.S. Pat. No. 10,617,485,issued Apr. 14, 2020, which is a continuation of U.S. patent applicationSer. No. 14/921,586, filed Oct. 23, 2015, now U.S. Pat. No. 10,321,968,issued Jun. 18, 2019, which applications are incorporated herein byreference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to containers for disposal ofmedical waste, and in particular to the disposal of contaminated items.The present invention may be a disposal system for use in a hospital orsimilar environment where contaminated items must be collected anddisposed of without creating a hazard for patients or hospitalpersonnel.

BACKGROUND OF THE INVENTION

In hospitals, clinics and similar institutions, contamination is ofutmost concern. Disposable, single use patient-care products, which usedto be the exception, are now the norm. Such hospital waste productsmight include surgical sharps, such as needles, syringes, scalpelblades, or the like, or might include gauzes, bandages, or sponges.

Various types of containers for hospital use have been developed forreceiving medical waste in a surgical operating room, pre-op or post-oproom, or a patient's room. These containers are particularly designed toprotect the user of such containers, such as doctors, nurses, or otherhospital personnel, from the hospital waste products that may bedisposed therein.

The proximal disposal of sharps in patient rooms has spawned a host ofspecialized sharps disposal containers. These containers are primarilydesigned to allow for the easy disposal of sharps in a manner that doesnot require excess effort, exposure to the sharp portion of a device andin which the disposed of sharp cannot be subsequently accessed. In mostinstances, the disposal system consists of a non-disposable cabinet orsupport that is more or less permanently affixed to a room surface(usually affixed to the wall with some type of anchor) and a disposablecontainer that fits within or is attached to the cabinet or support.Typically, the disposable container utilizes some type of door thatprevents unobstructed access to the interior of the container, butallows relatively easy disposal of the sharp.

It is important to prevent the user of a sharps container from beingaccidentally cut or punctured by its contents. Furthermore, it isimportant to prevent access to the contents of the container duringdisposal thereof.

Sharps containers have commonly been provided with a relatively largecircular opening through which sharps may be dropped in a verticalorientation for haphazard collection within the container. As thecontainer fills, the user runs the risk of a previously inserted sharpprotruding from the opening where it can stab the hand of the nextoperator inserting something into the container. Side walls may beconstructed of relatively soft or thin-walled material which could bepierced by any one of the haphazardly arranged needles within thecontainer thereby possibly exposing to infectious disease the nextperson brushing against the container. Other known sharps containershave a mailbox-like structure having a tilt pan which tips outwardly forreceiving a sharp and which tips inwardly for depositing the sharp inthe container. In this manner, the interior of the container is nevercompletely open to the room and the sharp can be disposed of with onesimple motion.

However, previous designs have been subject to jamming, improperfunction and manufacturing difficulties. For example, previous designsincluded lids with multiple distinct parts. In some examples, theseparts may be ultrasonically welded together. This creates extramanufacturing steps as well as unnecessarily using more plastic.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side perspective view of a sharps disposal system includinga permanent exterior cabinet and disposable interior container;

FIG. 2 is a side perspective view of the disposable interior containerwith the closure flap in a closed position;

FIG. 3 is a front perspective view of the disposable interior containerwith the closure flap in an opened position;

FIG. 4 is a side cut-away view of the interior of the disposablecontainer with the closure flap in a closed and locked position;

FIG. 5 is a side cut-away view of the interior of the disposablecontainer with the closure flap in a partially open position;

FIG. 6 is a side cut-away view of the interior of the disposablecontainer with the closure flap in a closed and permanently lockedposition;

FIG. 7 is a side cut-away view of the interior of the disposablecontainer with the closure flap in a completely open position;

FIG. 8 is a partially exploded side perspective view of the lid of thedisposable container;

FIG. 9 is an exploded side perspective view of the lid and componentparts of the disposable container;

FIG. 10 is a cross-sectional view of the axial hub of the closure flap;

FIG. 11 is a perspective view of a lid of a disposable interiorcontainer;

FIG. 12 is a perspective view of a sharps disposal system including apermanent exterior cabinet and disposable interior container;

FIG. 13 is partial perspective view of an underside of a closure flap ofthe container.

DETAILED DESCRIPTION

With reference to FIGS. 1-2 , the disposal system 2 of the presentinvention includes a locking exterior cabinet 4 that may be wall mountedand a disposable container 6 that is placed within the cabinet 4. Forexample, as shown in FIG. 1 , the cabinet 4 includes a bottom wall, rearwall 110, opposite upstanding side walls 104 and a front wall 102. Thefront wall 102 may be hinged to the side wall 104 or to the bottom wallsuch that the front wall can be swung open to remove the disposablecontainer 6 from the cabinet 4. The front wall 102 or corresponding sidewall 104 may include a locking mechanism (not shown) for securelylocking a disposable container 6 into the cabinet 4. The lockingmechanism may comprise a locking tab or latch, or it may include a keyedlock.

The cabinet 4 may be secured to a wall, desk, table or other surface.The securing mechanism may consist of screws or other fasteners insertedthrough the cabinet into the surface that are only accessible when thecabinet 4 is opened and the container 6 is removed. In this way, thecabinet could only be removed from the surface by someone with access toa cabinet key. Alternatively, an exterior frame, locking tabs or othermechanism may be provided to attach the cabinet to the surface.

As further shown in FIG. 1 , embodiments of the cabinet 4 may notinclude a top wall. Rather, the cabinet side walls 104 and rear wall 110may extend to and generally parallel to or below a top surface 16 of thecontainer 6. Alternatively, the cabinet may include a top wall that isdimensioned so as not to interfere with movement of a closure flap 12 ofthe container 6. The front wall 102 of the cabinet 4 may have an angledor sloped portion 108. The sloped portion 108 may be angled such thatthe top end portion 112 of the sloped portion 108 aligns generally withan upper portion 62 of the closure flap 12 when the closure flap 12 isin a closed and locked position, and the bottom end portion 114 of thesloped portion 108 aligns below an upper portion 62 of the closure flap12 when the closure flap is in an open position.

As show in FIGS. 2-4 , the disposable container 6 is preferably formedof four component parts including an open topped receptacle 8 forreceiving medical waste, a snap fit lid 10, a pivotal closure flap 12and a plurality of snap fit covers 14. The front portions of the lidside wall 18 may include a sloped portion 208 that generally correspondswith the sloped portion 108 of the cabinet front wall 102. Similarly,the sloped portion 208 may be angled such that the top portion 212 ofthe sloped portion 208 aligns generally with an upper portion 62 of theclosure flap 12 when the closure flap 12 is in a closed and lockedposition, and the bottom end portion 214 of the sloped portion 208aligns below an upper portion 62 of the closure flap 12 when the closureflap 12 is in an open position. The front shelf 22 provides a deck uponwhich the closure flap 12 may rest when in the open position.

As shown in FIGS. 3-4 , the lid 10 includes an upper wall 16, side walls18, a front wall 20, a front shelf 22, a rear wall 24, and a skirt 26extending around the lower portions of the lid 10 side and rear walls18, 24. Located in spaced relation between the front shelf 22, the frontportion 16 a of the upper wall 16 and front portion of the side walls18, an elongated opening 28 is provided for receiving the closure flap12 which is pivotally operable between a normal closed position, a fullyopened position and a permanently closed and locked position. Theclosure flap is sized such that when is in the normal closed position,the lower portion 60 of the closure flap 12 extends into the receptacle8 in spaced relation with the bottom wall (not shown) of the receptacle8 and the upper portion 62 of the closure flap 12 extends above the lidupper wall 16. Still further, the closure flap is sized such that whenin the open position, the lower portion 60 of the closure flap 12 sweepsimmediately adjacent to the interior rear wall 24 of the lid 10 and thedetent 72 of the upper portion of the closure flap approximatelycorresponds with the portion of the lid 10 where the front wall 20 andthe front shelf 22 meet.

The upper wall 16 of the lid 10 may have a generally planar and smoothsurface as illustrated in FIG. 3 . Alternatively, as shown in FIG. 11 ,embodiments of the lid 10 may include an upper wall 16 that incorporatesone or more decorative or structural features. For example, the upperwall 16 may incorporate ribs 92 that increase the structural rigidity ofthe upper wall. These ribs may be formed in a cross-hatch pattern 94 ora circular pattern 95, or some combination of these or other patterns asmay be appropriate to enhance the structure and/or aesthetics of theupper wall. Additionally, the lid 10 may incorporate ribs 96 that bridgethe gap between the side wall 18 and the lid lip 26 in order to provideadditional structural integrity to the lid.

As shown in FIG. 4 , the skirt 26 may include a horizontal portion 25that extends from the lid side 18 and rear walls 24. The skirt may alsoinclude a vertical portion 27 that extends below a flange 52 of thereceptacle 8. In some embodiments, as illustrated in FIG. 4 , the skirt26 may not include a horizontal portion adjacent to the front wall 20.And the skirt 26 may generally vertically from the edge of the frontshelf 22 to a lower edge 29 of the skirt. Alternatively, as illustratedin FIGS. 11-12 , embodiments of the lid 10 may include a skirthorizontal portion 25 that extends adjacent to the front wall 20 inaddition to the side walls 18 and rear wall. This horizontal portion 25may be positioned such that it accommodates the geometry of the frontwall 104 of the cabinet 4. For example, a top edge of the cabinet frontwall 104 may include a lip that extends partially over the horizontalportion of the skirt 26.

Turning to the interior surfaces of the lid 10, a plurality of featuresare provided to protect the user from accidental exposure to medicalwaste located within the receptacle 8. As shown in FIGS. 4-7 the frontportion 16 a of upper wall 16 interior, in spaced relation with theopening 28, includes a downward projection 30. As shown in FIGS. 4 and 5, the rear wall 24 interior includes a fixed cowl 32 which extendsdownwardly into the receptacle 8 to assist in guiding horizontallydisposed sharps placed on the closure flap 12 into the receptacle 8. Theprojection 30 and the cowl 32 restrict access into the interior of thecontainer 6 when the closure flap 12 is in a fully open position byconstricting access within the area that is the opening 28. The relativespacing of the front shelf 22, the downward projection 30 and the cowl32 define a limited opening 28 which restricts access to the interior ofthe container 6. The relative spacing of these features are dimensionedso that access to the interior of the container 6 is inhibited to theextent that it is difficult or impossible for an adult human hand topass through the opening 28. Still further, once the closure flap 12 islocked in a fully closed position, if the closure flap 12 is pried awayfrom the front portion 16 a of the lid upper wall 16 in an attempt togain access to the interior of the container 6, the projection 30 offersa further safety feature by restricting access to the interior of thecontainer.

The front shelf 22 includes a front portion that aligns with the frontwall 20 and a rear portion that includes a projection 220, which isdirected downward into the interior of the receptacle 8. When theclosure flap 12 is in a closed position, the medial portion of theclosure flap rests against the downward projection 220. As with otherlid interior features, downward projection 220 assists in restrictingaccess into the interior of the contain 6 by providing structuralsupport to the front shelf 22, as well as offers a further safetyfeature by restricting access to the interior of the container 6 in theevent an attempt to pry open the closure flap 12 is made in an attemptto gain access to the interior of the container

Additionally, in spaced relation with the interior upper wall 16 theinterior side walls 18 are provided a plurality of slots 34 throughwhich hooks 36 of the closure flap 12 are inserted to provide permanentclosure of the container 6 for transport and disposal. Once the hooks 36pass through the slots 34, movement of the closure flap 12 is blocked sothat force applied against the closure flap 12 will not move the closureflap 12 from a closed position to an open position.

As shown in FIG. 8 , the lid 10 may also include an opening 38 throughwhich an axial hub 42 of the closure flap 12 may be inserted. Inaddition, the lid may include openings 40 through which locking tabs 44of the snap fit cover 14 extend, as discussed in greater detail below.

The receptacle 8 includes a bottom wall, front wall 46, rear wall 48 andside walls 50. As shown in FIG. 4 , the upper portions of the receptacle8 front, rear and side walls, 46, 48, 50 include a flange 52 thatextends outwardly and downwardly from the top edge of the side walls.The flange is adapted to receive corresponding inwardly extendinglocking fingers 54 of the lid skirt 26 to provide a permanent snap fitconnection between the lid 10 and receptacle 8.

As shown in FIGS. 8-9 , the upper edges of the receptacle 8 side walls48 may include locking fingers 56 that are inserted into throughopenings 58 located on the lid 10 side wall skirt 26 permanent provide asnap fit connection between the receptacle 8 and lid 10.

Additional embodiments of the disposal system may include viewing portsin the one or more of the front 102 and side 104 walls of the cabinet 4.These view ports correspond to view ports 230, 232 (FIG. 3 ) that may belocated in the front 46 and side 50 walls of the receptacle 8. Theviewing ports permit a user to view the contents of the system anddetermine empty/full status prior to attempted use.

FIGS. 4-7 illustrate the relative positions of the closure flap 12 inthe assembled container 6. During use, the closure flap 12 is pivotallymovable between a normal closed, unlocked position (not shown), and afully opened position as shown in FIG. 7 . As shown in FIG. 4 , theclosure flap 12 may be permanently closed and locked for transport anddisposal. In the normal closed position, the upper portion 62 of theclosure flap does not touch the upper wall 16 of the lid 10; thecontainer is never fully closed and locked until the hooks 36 areinserted into through slots 34 at which point the container 6 is lockedfor transport and disposal. When in the locked position, the upperportion 62 of the closure flap 12 rests against the front portion 16 aof the upper wall 16 of the lid 10 and the closure flap detent 72 restsagainst the interior downward projection 30.

The closure flap 12 includes a lower portion 60, an upper portion 62,and side portions/walls 64 as well as interior 66 and exterior 68surfaces. The upper portion 62 of the closure flap 12 includes a centraltab 70, which is operable by a user to displace the closure flap 12between normal closed and open positions. When the tab 70 is pivotallydirected downward toward the front shelf 22, the closure flap 12 opens.When released, the closure flap 12 returns to its normal closedposition. A detent 72 is provided is provided adjacent to the upper flapportion 62, which when the closure flap 12 is in a permanently lockedposition rests against the downward projection 30 of an interior upperwall 16 of the lid 10. With respect to the interior surface 66 of theclosure flap, the detent 72 provides an inclined surface 74 which workswith gravity to direct sharps into the container 6 when the closure flap12 is moved from an open position to a normal closed position.

The pivotal operation of the closure flap 12 is provided by a pluralityof annular axial hubs 42 located at the side edges 64 of the flap inspaced relation with the upper portion 62 of the closure flap 12 suchthat the mass of lower portion 60 of the closure flap 12 exceeds themass of the upper portion 62 with the result that the closure flap 12 isgravitationally biased to its normal closed position when released.

As shown in FIG. 13 , the closure flap 12 may include various ribs thatprovide structural rigidity to the closure flap. For example, the flapmay include one or more ribs 122 extending across the flap 12 betweenhubs 42. The flap may also include additional ribs arranged in variousappropriate patterns on other portions of the flap. FIG. 13 illustrates,for example, ribs 124 arranged in a generally rectangular pattern acrossan underside of the lower portion 60 of the flap. In addition, the flap12 may include a rib 126 that extends from the hub 42 along an edge ofthe upper portion 62. This rib 126 may include a notch 128 that aids inthe installation of the flap 12 into the lid.

As illustrated in FIGS. 8-10 , axial hubs 42 are inserted throughopenings 38 in the lid 10. The axial hubs 42 include a bearing surface87 and a flange 88. The flange has a larger diameter than the bearingsurface 87. The openings 38 include a circular portion 39 at an upperend of the opening and a generally rectangular lower portion 41. Thelower opening portion 41 may extend through the side wall 18 as well asthe skirt 26 adjacent the side wall. In this manner, the hub 42 can beinserted through the lower opening 41 and slid upward such that the hubbearing surface 87 engages with the circular opening 39. The circularopening 39 has a diameter that is less that the hub flange 88 so thatthe flange engages an outside surface of wall 18 adjacent to thesemicircular opening 39. The semicircular opening 39 may extend over anarc of 90 degrees, an arc of 180 degrees or an arc of greater than 180degrees so as to have a snap fit the hub bearing surface 87.

Snap fit covers 14 are provided to maintain the axial hubs 42 inposition once inserted through the through openings 38 of the lid 10.The covers 14 include an exterior wall 76, an interior wall 78, sidewalls 80 and lower wall 82. Locking tabs 44 extending from the sidewalls 78 in spaced relation with the lower wall 82 and an annularbushing 84 extends from the interior wall 78. After the axial hubs 42 ofthe closure flap 12 are inserted into the through openings 38 from theinterior of the lid 10, the annular bushings 84 of the covers 14 arealigned with the annular opening 86 of the axial hubs 42 and the lockingtabs 44 are aligned with the through openings 40 of the lid 10. Thediameter of the annular bushing 84 is sized for insertion into theannular opening 86 of the axial hub 42. Once aligned and snapped inplace, the cover 14 provides the structural support for the pivotalrotation of the closure flap 12.

What is claimed is:
 1. A container for disposal of medical wastecomprising: a cabinet comprising a first wall; and a disposablecontainer positioned within the cabinet, the disposable containercomprising: a receptacle having an open top, a bottom wall and a sidewall; a lid attached to the receptacle, the lid comprising a top wall, aback wall, a front wall having an opening sized to permit theintroduction of medical waste into the receptacle, and a side wall; aclosure flap movable between an open position and a closed position, theclosure flap comprising an axial hub extending from a side of theclosure flap through an opening in the lid side wall; and a coverattached to an outside surface of the lid side wall and covering aportion of the closure flap axial hub that extends through the lid sidewall opening; wherein the cabinet is selectively openable to remove thedisposable container, and the cabinet first wall restricts access to thedisposable container cover.
 2. The container of claim 1 wherein thecabinet further comprises a second wall and a hinge connecting the firstwall with the second wall.
 3. The container of claim 2 wherein thesecond wall pivots on the hinge to open the cabinet.
 4. The container ofclaim 3 wherein the first wall is a side wall and the second wall is afront wall.
 5. The container of claim 1 wherein the cabinet furthercomprises a second wall, a third wall, and a hinge connecting the secondwall with the third wall.
 6. The container of claim 5 wherein the secondwall is a front wall and the third wall is a bottom wall.
 7. Thecontainer of claim 1 wherein the cabinet further comprises a fastenersecuring the cabinet to a surface.
 8. The container of claim 7 whereinthe fastener is only accessible when the cabinet is open.
 9. A containerfor disposal of medical waste comprising: a cabinet comprising a bottomwall, a rear wall, a side wall, and a front wall; and a disposablecontainer positioned within the cabinet, the disposable containercomprising: a receptacle having an open top, a bottom wall and a sidewall; a lid attached to the receptacle, the lid comprising a top wall, aback wall, a front wall having an opening sized to permit theintroduction of medical waste into the receptacle, and a side wall; aclosure flap movable between an open position and a closed position, theclosure flap comprising an axial hub extending from a side of theclosure flap through an opening in the lid side wall; and a coverattached to an outside surface of the lid side wall and covering aportion of the closure flap axial hub that extends through the lid sidewall opening; wherein the cabinet side wall covers and restricts accessto the disposable container cover.
 10. The container of claim 9 whereinthe cabinet is selectively opened to remove the disposable container.11. The container of claim 10 wherein the cabinet further comprises ahinge.
 12. The container of claim 11 wherein the front wall of thecabinet is hinged to the side wall of the cabinet, and the front wallswings open to remove the disposable container from the cabinet.
 13. Thecontainer of claim 11 wherein the front wall of the cabinet is hinged tothe bottom wall of the cabinet, and the front wall swings open to removethe disposable container from the cabinet.
 14. The container of claim 10wherein the cabinet further comprises a lock.
 15. The container of claim14 wherein the lock comprises a keyed lock.
 16. The container of claim10 wherein the cabinet is secured to a surface.
 17. The container ofclaim 16 wherein the surface is a surface of an object chosen from thegroup of objects consisting of a wall, a desk, a table, a counter, adoor, or a cabinet.
 18. The container of claim 16 wherein the cabinet issecured to the surface by a fastener.
 19. The container of claim 18wherein the fastener is a mechanism chosen from the group of mechanismsconsisting of a screw, a nail, adhesive, or hook-and-loop.
 20. Thecontainer of claim 11 wherein the fastener is only accessible when thecabinet is opened and the disposable container is removed.